Article of apparel including apertures

ABSTRACT

An article of apparel is formed of a woven textile structure including channels formed by selectively removing warp and/or weft yarns from the textile structure. Specifically, the removed yarns define engineered apertures within textile structure. The apertures, oriented along the warp and weft directions, provide an article of apparel with good breathability and air permeability properties.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to provisional application No.61/934,962, entitled “Woven Garment Including Engineered Apertures” andfiled on 3 Feb. 2014. The disclosure of the above application is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention is directed toward apparel and, in particular, toan article of apparel that incorporates a textile including aperturesproviding air permeability and breathability to the article of apparel.

BACKGROUND OF THE INVENTION

Textiles are manufactured from fibers, filaments, or yarns. Textiles areproduced through various production methods, including nonwovenprocesses, knitting processes, and weaving processes. Nonwoven textilesare webs of fibers connected via bonding, fusing, or interlocking Knittextiles include consecutive rows of loops, called stitches. As each rowprogresses, a new loop is pulled through an existing loop. Woventextiles include a set of lengthwise threads (called the warp)interlaced with a set of crossing threads (called the weft). Knittedtextiles are loose, including spaces between the loops that permit airto pass therethrough. Accordingly, the knitting process forms a highlybreathable fabric. In contrast, woven textiles, while strong anddurable, are dense and tight. Consequently, woven textiles possess poorbreathability. Thus, it would be desirable to form a woven garmenthaving improved breathability of the garment.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed toward an article of apparel formedfrom a textile including a plurality of engineered apertures. In anembodiment, the textile is a woven fabric including apertures formed byselectively removing warp and/or weft yarns from the textile structure.By way of example, the yarns may be dissolved with a dissolving agent.The apertures are aligned along the channel left by the removed yarn.Accordingly, the plurality of apertures is oriented along the warpdirection and/or weft direction of the textile structure. The textile isincorporated into and/or forms an article of apparel such as pants,shirts, suits, outerwear, footwear, sports jerseys, etc. The resultingarticle of apparel possesses high breathability and/or air permability,increasing the comfort of the wearer.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A illustrates a schematic of a woven textile in accordance withthe invention.

FIG. 1B illustrates a cross sectional view of the textile of FIG. 1A,taken along line 1B.

FIG. 1C illustrates the textile of FIG. 1A, showing dissolvable yarnswithin the structure.

FIG. 1D illustrates the textile of FIG. 1C, showing dissolved yarns andapertures in the textile.

FIG. 2 illustrates a schematic of the textile in accordance with theinvention, showing removal of a yarn from the structure and theformation of an aperture.

FIG. 3A illustrates a suit jacket in accordance with the invention.

FIG. 3B is a close-up view of the suit jacket of FIG. 3A, showing thejacket lining.

FIG. 4A is an isolated, close-up view of the suit jacket exterior,showing the engineered apertures oriented along the warp and weftdirections of the textile.

FIG. 4B is a close-up view of the jacket shown in FIG. 4A taken from boxlabeled 4B.

FIG. 5A is a close-up view of the suit jacket lining, showing theengineered apertures.

FIG. 5B is a close-up view of the lining textile of FIG. 5A, taken frombox 5B.

FIG. 5C illustrates an isolated view of the lining textile showing theengineered apertures.

Like reference numerals have been used to identify like elementsthroughout this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

An article of apparel in accordance with the present invention is formedfrom a textile structure including yarn. Yarn, which possesses asubstantial length and small cross-section, is formed from filaments orfibers. Filaments, which have an indefinite length, are generally formedfrom synthetic polymers such as rayon, nylon, and polyester. Typically,filaments are combined with other filaments to produce yarn.Accordingly, yarn may be formed from filaments of the same material, ormay be formed from filaments of different materials. Fibers have arelatively short length and require spinning or twisting processes toproduce a yarn of suitable length. Common examples of fibers are cottonand wool. As with filaments, yarns may be formed from fibers of the sameor different materials.

Several types of yarn may be utilized. Spun yarn includes a number offibers twisted together. Zero-twist yarn includes a number of filamentslaid together without twist. Twist yarn includes a number of filamentslaid together with a degree of twist. A monofilament yarn includes asingle filament with or without twist.

The textile structure, moreover, may be a woven fabric. In weaving, twoor more yarns are interlaced so that the yarns they cross each other atright angles to produce woven fabric. The warp yarns (ends) runlengthwise (longitudinally) in the fabric, while the weft yarns (fillingthreads or picks) run from side to side (transversely). The set oflengthwise threads (called the warp) are interlaced with a set ofcrossing threads (called the weft) via a loom. Several types of weavingpatterns may be utilized to form the textile structure. In plainweaving, the warp and weft are aligned so they form a simple crisscrosspattern. Specifically, each weft thread crosses the warp threads, with afirst warp thread alternately going over one warp thread and under theadjacent warp thread. The adjacent weft thread inverts this process,with the weft thread crossing under the warp thread the previous threadcrossed over.

A basket weave, similar to the plain weave, includes two or more warpand filling threads woven side by side to resemble a plaited basket. Ina satin weave, the face of the fabric consists almost completely of warpor filling floats produced in the repeat of the weave. A twill weave ischaracterized by diagonal lines produced by a series of floats staggeredin the warp direction. A double weave includes two systems of warp orfilling threads combined such that only one is visible on either side. Aleno weave includes warp yarns arranged in pairs, with one warp yarntwisted around another warp yarn between picks of filling yarn. A pileweave includes an additional set of yarns, either warp or filling, thatfloats on the surface. The surface yarns are cut to form a pile.

Woven textiles, while strong and durable, are dense and tight.Consequently, woven textiles have poor breathability and/poor airpermeability. Breathability is the ability of a fabric to allow moisturevapor to pass through it. Air permeability, in contrast, relates to theporosity or the ease with which air passes through the textile. Both airpermeability and breathability influence the comfort, warmth, orcoolness of a fabric.

In accordance with the invention, the textile structure includes aplurality of engineered apertures that improve the air permeabilityand/or the breathability of the textile. An engineered aperture (alsocalled a dissolution void) within the context of the invention is anopening in the woven textile structure created by removal of one or moreweft yarns and/or one or more warp yarns from the structure. Inparticular, an engineered aperture is an opening formed by removingintersecting weft and warp yarns. For example, the yarns may be removedin a non-mechanical manner. In an embodiment, the yarns are removedchemically, e.g., via dissolution (explained in greater detail below).The apertures pass completely through the textile structure to permitfluid (air and/or water vapor) to pass therethrough.

An engineered aperture is not a discrete opening in the fabric formedmechanically, e.g., by means such as punching or cutting. An engineeredaperture, moreover, is not an opening existing as a result of thetextile formation (e.g., a weaving or knitting process) such as a meshfabric. Furthermore, an engineered aperture is not an opening formed bychanging a physical parameter of the yarns, e.g., by changing yarndimensions (e.g., via water absorption). Finally, an engineered apertureis not an opening formed by etching with a mask. In etching, causticchemical action removes a discrete area of the fabric to form theopening. The etchant merely breaks the weft or warp yarn—the weft orwarp yarn is not completely removed.

The textile structure utilized to form the article of apparel includes aremovable yarn and a non-removable yarn. Specifically, the textilestructure is a woven fabric including a dissolvable yarn and an inert ornon-dissolvable yarn. The dissolvable yarn is formed of a natural orsynthetic polymer configured or selected to dissolve in dissolvingagent. In an embodiment, the dissolvable yarn may be a water solubleyarn such as polyvinyl alcohol (PVA). Accordingly, the dissolving agentmay be water (e.g., water elevated to a predetermined temperature). Inanother embodiment, the dissolving agent is aluminum sulfate or acidsodium sulfate, and the dissolvable yarn is formed of cellulose fibers(e.g., rayon, lyocell, and cotton) or a polyamide fiber (e.g.,6,6-nylon). In another embodiment, the dissolvable yarn is modifiedpolyester and the dissolving agent is sodium hydroxide.

The inert yarn is formed of a material (e.g., a natural or syntheticpolymer) that does not dissolve in the dissolving agent capable ofdissolving the dissolvable yarn. By way of example, the inert yarn isincludes polyurethane or polyester (e.g., unmodified polyester).

The manner of forming the article of apparel is explained with referenceto the figures. Referring to FIGS. 1A and 1B, the textile structure 200is formed via weaving; accordingly, it includes a plurality of weftyarns 205 interwoven with a plurality of warp yarns 210 such that thewarp and weft yarns cross at substantially right angles to each other.As seen best in FIG. 1C, the plurality of weft yarns 205 includesdissolvable yarns 215A and inert yarns 215B. Similarly, the plurality ofwarp yarns 210 includes both dissolvable yarns 220A and inert yarns220B.

After the formation of the textile 200, the dissolvable yarns 215A, 220Aand inert yarns 215B, 220B are exposed to a dissolving agent. Thedissolving agent may be applied via any process suitable for itsdescribed purpose (i.e., to apply the agent such that it contacts theentire textile). In an embodiment, the dissolving agent is sprayed ontothe textile structure 200. In another embodiment, the textile structure200 is drawn though a bath containing the dissolving agent. That is,both the dissolvable yarns 215A, 215B and the inert yarns 215B, 220Bcome into contact with the dissolving agent. While the inert yarns 215B,220B remain intact, the dissolvable yarns 215A, 220A dissolve in thedissolving agent (i.e., the yarns fall into solution with the solvent).Consequently, as shown in FIG. 1D, selected yarns (i.e., the dissolvableyarns 215A, 220A) are removed from the textile structure 200, leaving anelongated weft channel or gap 225 and an elongated warp channel or gap230 where the yarns 215A, 220A existed. Along these gaps 225, 230 arethe engineered apertures.

In an embodiment, two types of engineered apertures are formed, namely,a first or small engineered aperture 235 possessing a first, size ordiameter and a second or large engineered aperture 240 possessing asecond size or diameter, the second diameter being greater than thefirst diameter. In general, the small engineered apertures 235 existalong those areas where only the weft yarn 205 or warp yarn 210 isremoved. The large engineered aperture 240 exists at the intersection ofremoved weft 205 and warp 210 yarns. That is, the areas of the textilestructure 200 where both the warp 205 and weft 210 yarns are removeddefine the large engineered apertures 240. As shown below, the shape ofthe engineered apertures (and, in particular, the large apertures 240)may be polygonal (e.g., square or rectangular).

While FIG. 1D illustrates a textile with both weft 205 and warp 210yarns are removed, it should be understood that selected yarns from oneset of yarns—either the weft yarns or the warp yarns—may be removed.This is illustrated in FIG. 2 (dissolved weft yarn 220A shown inphantom). It should further be understood that dissolvable 215A, 220Aand inert 215B, 220B yarns may be positioned within the textilestructure 200 in any manner suitable for its described purpose. Forexample, the dissolvable and inert yarns may alternate along thelongitudinal or transverse dimensions of the textile structure 200. Inanother embodiment, multiple dissolvable yarns are positioned insuccession, with a plurality of dissolvable yarns being adjacent eachother. Each plurality of dissolvable yarns may be separated by aplurality of inert yarns.

In this manner, the textile structure 200—and thus the resulting articleof apparel—includes a plurality of engineered apertures 235, 240 alignedalong the textile's weft direction and/or warp direction. Specifically,a first set of engineered apertures is oriented in the transverse fabricdirection, being aligned along the longitudinal axis of the elongatedgap formed by the dissolved weft yarn 205 (indicated by arrow W_(weft)).Similarly, a second set of engineered apertures is oriented in thelongitudinal fabric direction, being generally aligned along thelongitudinal axis of the elongated gap formed by the dissolved warp yarn210 (indicated by arrow W_(warp)).

The resulting textile, then, may include alternating small apertures 235and large diameter apertures 240 along the warp axis W_(warp) or weftaxis W_(weft). By way of example, a large aperture 240 may be separatedfrom an adjacent large aperture 240 by a plurality of small apertures235. In an embodiment, the small apertures possess a diameter that is100 μm or less, while the large apertures possess a diameter greaterthan 100 μm (e.g., 200 to 5,000 μm).

The article of apparel formed utilizing the above textile 200 is notonly durable, but also possesses a high degree of air permeabilityand/or breathability. In contrast, if mechanical means were utilized toperforate the fabric, the yarns would unravel, creating a run in thetextile (and thus the article of apparel). Circular knit fabrics,moreover, are prone to runs when the fabric is mechanically perforated.That is, should the fabric be perforated at a point, stitches proximatethe point will unravel, creating a run/tear in the fabric and/or causingthe yarns to fray. The engineered apertures of the invention, however,do not weaken the interwoven connection of the yarns. Accordingly, theresulting article of apparel remains strong, and is not subject tofraying/running Thus, forming the textile 200 so as to have engineeredapertures results in fabric having increased durability and strength.

The resulting process further results in textile 200 that is lighterthan a similar garment that does not contain engineered apertures, i.e.,a garment lacking apertures or a garment that is mechanicallyperforated. As noted above, the process completely removes weft yarns205 and/or warp yarns 210 from the textile 200. Accordingly, the overallweight of the textile (and the resulting article of apparel) is reduced.This is in contrast to etching, in which an etchant is selectivelyplaced at desired locations to remove a portion of a weft or warp yarn.The resulting textile remains heavy since a substantial portion of theweft and/or warp yarn remains (i.e., etching only breaks the connectionalong the yarn). Similarly, perforating the textile 200 via mechanicalmeans such as punching merely breaks the connection along the yarn 205,210. Since the yarn is still present in the textile, it adds to itsweight. This disadvantage is avoided with the textile 200 of the presentinvention.

An article of apparel including the textile with engineered apertures235, 240 is illustrated in FIGS. 3A, 3B, 4A, 4B, 5A, 5B, and 5C.Referring to FIGS. 3A and 3B, the suit jacket 105 includes an exteriorshell 405 and an interior lining 410. As shown in FIGS. 4A and 4B, theshell 405 is formed of woven textile including dissolved weft sections225 and dissolved warp sections 230 as described above. Where only onedirectional yarn (warp or weft) is dissolved, areas of small apertures235 result (i.e., a plurality of small apertures is formed). Where bothdirectional yarns 235, 240 are dissolved, i.e., at the intersectionpoint of weft and warp, a large aperture 240 is formed. Accordingly, asseen in the figures, a dissolved weft channel 225 includes alignedapertures 235, 240 oriented in the weft direction. Similarly, thedissolved warp channel 230 includes aligned apertures 235, 240 orientedin the warp direction. As shown, the apertures 235, 240 may beconfigured to alternate in the warp or weft direction, with runs of aplurality of small diameter apertures 235 being interrupted periodicallyby a large diameter aperture 240.

Similarly, the lining 410 is formed from textile including dissolvedweft sections 225 and dissolved warp sections 230 as described above.Where only one directional yarn (warp or weft) is dissolved, areas ofsmall apertures 235 result (i.e., a plurality of small apertures isformed). Where both directional yarns are dissolved, i.e., at theintersection point of weft and warp yarns that were dissolved, a largeaperture 240 is formed. Accordingly, as seen in the figures, a dissolvedweft channel 225 includes aligned apertures 235, 240 oriented in theweft direction. Similarly, the dissolved warp channel 230 includesaligned apertures 235, 240 oriented in the warp direction. As shown, theapertures 235, 240 may be configured to alternate in the warp or weftdirection, with a collection of small diameter apertures 235 beingseparated by large diameter apertures 240.

The article of apparel may be a multilayer garment including a firstlayer including engineered apertures coupled (e.g., connected viastitching) a second layer including engineered apertures. The aperturesof the first layer may align with the apertures of the second layer.Alternatively, the apertures of the first layer may be offset withrespect to the apertures of the second layer. A cavity may exist betweenthe first that second layers. The cavity may permit fluid flow aroundthe fabric. In another embodiment, the cavity may be filled withinsulation.

The resulting textile including engineered apertures provides a woventextile with improved air permeability and/or breathability. The weightof the resulting article of apparel, furthermore, is less than the samearticle of apparel without the engineered apertures or with aperturesformed mechanically (laser perforation, punching, etc.)

While the invention has been described in detail and with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope thereof. In other embodiments, thedissolving agent may be placed onto selected yarns to initiatedissolution of those yarns while leaving the others intact. For example,various printing processes may be used to selectively deposit thedissolving agent onto the textile yarns. Additionally, processes such aschemical vapor deposition may be utilized. Accordingly, only the yarnsto be dissolved would be contacted by the dissolving agent. With thisconfiguration, the entire textile may be formed of dissolvable yarns,with the yarns selectively dissolved by selective placement of thedissolving agent. The yarns may possess any dimensions (diameter/shape)suitable for its descried purpose. In an embodiment, the dernier of eachof the warp and weft yarns are the same. Alternatively, the dernier ofthe warp yarn may be greater than the dernier of the weft yarn, or viceversa. By way of example the weft yarn may possess a larger dernier thanthe warp yarn.

The engineered apertures are not formed via mechanical processes such aslaser cutting, punching, etc. The engineered apertures are further notformed of an etching process involving an aperture mask.

The aperture dimensions (diameter and shape) may be any diametersuitable for its described purpose. The aperture dimensions may beselected by selecting yarns of a desired denier (the larger the denier,the larger the aperture). The aperture dimensions may be selected toimpart air permeability or breathability, while being waterproof (e.g.,apertures having a diameter of less than 100 μm), based on the fact thatwater droplets generally possess a diameter of 100 μm or more. In anembodiment, the apertures range in size from 0.0004 μm to 1000 μm. Inanother embodiment, the apertures range in size from 1 mm to 5 mm.

The ratio of the diameter of the small aperture to the large aperturemay be 1:2. In other embodiments, the ratio of the diameter of the smallaperture to the large aperture is approximately 1:1.5 to 1:5.

The density of engineered apertures within the textile structure may beselected to provide the desired amount of air permeability and/orbreathability. In and embodiment, the textile includes approximately 10engineered apertures per square centimeter of textile surface.

The article of apparel includes garments such as headwear, outerwear(coats, jackets, and gloves), pants, shorts, shirts, socks, footwear,etc. In an embodiment, the article of apparel is a suit including ajacket and pants. The suit jacket includes a torso portion, a first armportion, and a second arm portion. The pants include a waist portion, afirst leg portion, and a second leg potion. The entire article ofapparel may include the engineered apertures. For example, each pant legof the pants, as well as the torso and arm portions may include theengineered apertures.

Thus, it is intended that the present invention covers the modificationsand variations of this invention provided they come within the scope ofthe appended claims and their equivalents. It is to be understood thatterms such as “top,” “bottom,” “front,” “rear,” “side,” “height,”“length,” “width,” “upper,” “lower,” “interior,” “exterior,” “medial,”“lateral,” and the like as may be used herein, merely describe points ofreference and do not limit the present invention to any particularorientation or configuration.

What is claimed is:
 1. An article of apparel comprising a woven textilestructure including a plurality of warp yarns and a plurality of weftyarns, a warp channel defined by an elongated gap along the warp of thetextile structure, the warp channel formed by removal of a warp yarn ofthe plurality of warp yarns, a weft channel defined by an elongated gapalong the weft of the textile structure, the weft channel formed byremoved of a weft yarn from the plurality of weft yarns an engineeredaperture disposed at an intersection of the warp channel and the weftchannel, the engineered aperture permitting flow of fluid through thetextile structure.
 2. The article of apparel according to claim 1,wherein the plurality of warp yarns comprises a dissolving yarndissolvable by a dissolving agent and an inert yarn not dissolvable bythe dissolving agent.
 3. The article of apparel according to claim 2,wherein the plurality of weft yarns comprises a dissolvable yarndissolvable by a dissolving agent and an inert yarn not dissolvable bythe dissolving agent.
 4. The article of apparel according to claim 3,wherein the dissolvable yarn comprises modified polyester and dissolvingagent comprises sodium hydroxide.
 5. The article of apparel according toclaim 1, wherein the textile structure further comprises: a plurality ofweft channels disposed at predetermined locations along the textilestructure, wherein adjacent weft channels of the plurality of weftchannels are separated by one or more weft yarns; and a plurality ofwarp channels disposed at predetermined locations along the textilestructure, wherein adjacent warp channels of the plurality of warpchannels are separated by one or more warp yarns.
 6. The article ofapparel according to claim 5, wherein: the plurality of weft channelsand the plurality of warp channels cooperate to form a plurality ofengineered apertures oriented in spaced relation along the textilestructure; and the plurality of engineered apertures permit passage offluid through the textile structure.
 7. The article of apparel accordingto claim 6, wherein the fluid is air.
 8. The article of apparelaccording to claim 6, wherein the fluid is water vapor.
 9. The articleof apparel according to claim 6, wherein the plurality of engineeredapertures comprises: a first engineered aperture possessing a firstdiameter; and a second engineered aperture possessing a second diameter,wherein the second diameter is greater than the first aperture.
 10. Thearticle of apparel according to claim 9, wherein ratio of the seconddiameter size to the first diameter is approximately 1.5:1 to 5:1. 11.The article of apparel according to claim 9, wherein one of the first orsecond diameters is greater than 100 μm.
 12. The article of apparelaccording to claim 1, wherein the fluid at least one of fluid or watervapor.
 13. The article of apparel according to claim 12, wherein each ofthe warp yarn and the weft yarn comprises a synthetic polymer.
 14. Thearticle of apparel according to claim 1, comprising a plurality ofengineered apertures oriented along each of the warp channel and theweft channel.
 15. An article of apparel formed of a textile, the textilecomprising: a plurality of warp yarns, said plurality including an inertwarp yarn and a dissolvable warp yarn; a plurality of weft yarnsinterwoven with the plurality of warp yarns; and a plurality ofdissolution voids formed via exposing the plurality of warp yarns to adissolving agent to dissolve the dissolvable warp yarn.
 16. The articleof apparel according to claim 15, wherein: the plurality of weft yarnsincludes an inert yarn and a dissolvable weft yarn; the dissolving agentfurther dissolves the dissolvable weft yarn.
 17. The article of apparelaccording to claim 16, wherein: the dissolvable warp yarn comprisesmodified polyester; and the dissolving agent comprises sodium hydroxide.18. The article of apparel according to claim 17, wherein the inert yarnis not dissolved by the dissolving agent.
 19. The article of apparelaccording to claim 15, wherein the article of apparel weighs less thanthe same or similar article of apparel including apertures formedmechanically.